Hydraulic supply hose including an integral tensile load member

ABSTRACT

A supply hose includes a core tube, a first layer, a second layer, and a sheath. The core tube defines a hollow interior that surrounds a central axis and is configured to transport fluid therethrough. The first layer and/or the second layer provide tensile strength to the supply line. The first layer is disposed about the core tube and includes a plurality of first fibers. The first fibers are braided about the core tube at a first angle, relative to the central axis. The second layer is disposed directly on the exterior surface of the first layer and includes a plurality of second fibers. The second fibers are braided about the exterior surface of the first layer at a second angle, relative to the central axis. The sheath may be disposed about the second layer.

TECHNICAL FIELD

The present invention relates to a hydraulic supply hose including anintegral tensile load member.

BACKGROUND OF THE INVENTION

A pump is typically connected to a length of pipe and inserted down intoa well. The length of pipe may be formed from a plurality of individualsmaller lengths of pipe that are attached to one another as the pump islowered down into the well. In addition, the weight of the pump may besupported by the pipe. For example, a length of pipe that isapproximately 2,000 feet long may be attached to the pump that isdisposed approximately 2,000 feet down in the well. To achieve the 2,000foot length of pipe, an individual smaller length of pipe is attached tothe pump and lowered down into the well. Next, another individual smalllength of pipe is attached to the first length of pipe so that the pumpcan be lowered a little further down into the well. This processcontinues until the desired depth of 2,000 feet is achieved. Likewise,to remove the pump from the well, the process is reversed and theindividual smaller lengths of pipe are removed from one another as thepump is raised from the well. Attaching and detaching the individuallengths of pipe together to position the pump within the well takes asignificant amount of time and labor.

SUMMARY OF THE INVENTION

A hydraulic supply hose extends along a central axis and defines ahollow interior. The supply hose includes a first layer and a secondlayer. The first layer includes a plurality of first fibers that arebraided about the hollow interior at a first angle, relative to thecentral axis. The second layer includes a plurality of second fibersthat are braided about the hollow interior at a second angle, relativeto the central axis. The first angle is substantially greater than thesecond angle.

A supply hose includes a core tube, a first layer, a second layer, and asheath. The core tube extends along a central axis and defines a hollowinterior configured for transporting fluid therethrough. The first layeris disposed about the core tube and presents an exterior surface. Thefirst layer includes a plurality of first fibers that are braided aboutthe core tube at a first angle of between 52 degrees and 56 degrees,relative to the central axis. The second layer is disposed directly onthe exterior surface of the first layer. The second layer includes aplurality of second fibers that are braided about the exterior surfaceof the first layer at a second angle of between 28 degrees and 32degrees, relative to the central axis. The sheath is disposed about thesecond layer.

A method of installing a pump in a well includes providing a supply hosedefining a hollow interior that is configured for fluid to flowtherethrough. The supply hose includes a plurality of first fibers thatare braided about the hollow interior at a first angle, relative to thecentral axis, and a plurality of second fibers that are braided aboutthe first fibers at a second angle, relative to the central axis. Thesupply hose is attached to the pump such that the supply hose is influid communication with the pump. The pump is lowered into the wellwith the supply hose such that the weight of the pump is substantiallysupported by the supply hose.

By providing a supply hose with significant strength, the supply hosemay be able to significantly support the weight of a pump within a well.Not only will the supply hose be able to support the weight of the pump,but the hose is able to be unwound as the pump is lowered into the well.By lowering the pump into the well by unwinding the hose, significantsavings may be achieved by reducing the amount of time and labor that isrequired to lower the pump into the well.

The above features and advantages and other features and advantages ofthe present invention are readily apparent from the following detaileddescription of the best modes for carrying out the invention when takenin connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the figures, which are exemplary embodiments andwherein like elements are numbered alike:

FIG. 1 is a schematic side view of a hydraulic supply hose, partiallycut away to show a core tube, a first layer, a second layer, and asheath;

FIG. 2 is a partial cross-sectional end view of the hose of FIG. 1;

FIG. 3 is a chart showing load versus tensile strain for the supplyhose; and

FIG. 4 is a schematic cross-sectional side view of a pump disposedwithin a well in the ground with the pump being operatively supported bythe supply hose.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings, wherein like reference numbers refer to likecomponents, FIG. 1 shows a hydraulic supply hose at 10. The hose may beused to transport fluid to a down-hole well 11 via a submersible pump13, as illustrated in FIG. 4. The well 11 may be dug into the ground 17.The supply hose 10 may be attached to the pump and lowered into the well11, as shown in FIG. 4. The supply hose 10 may be wound around a hosereel 15 and unrolled to lower the pump 13 into the well 11. The supplyhose 10 is configured such that the weight of the pump 13 issubstantially supported by the supply hose 10. For example, if the well11 has a depth of 2,000 feet (i.e., 609.6 meters), the supply hose 10supports the weight of the pump 13. This means that the supply hose 10substantially supports the weight of the pump 13, the length of thesupply hose 10, and any fluid contained therein at the depth of 2,000feet. Therefore, supply hose 10 is configured to have sufficient tensilestrength to substantially support the weight of the pump 13 at thedesired depth of the well 11. The supply hose 10 may support at least4,000 pounds (lbf) with a tensile strain up to least 10% before failure,as shown in FIG. 3. However, it should be appreciated that the supplyhose 10 may be used in other applications as known to those skilled inthe art.

The supply hose 10 extends along a central axis 14 and defines a hollowinterior 16 that is configured to transport fluid therethrough. Thesupply hose 10 includes a core tube 12 that surrounds the central axis14 and defines the hollow interior 16 therein. The core tube 12 may beformed as a co-extruded tube having a core layer 18 and a backing layer20. The core layer 18 defines the hollow interior 16 and the backinglayer 20 surrounds the core layer 18. Therefore, the core layer 18 andthe backing layer 20 are co-extruded such that the backing layer 20 isbonded to the core layer 18. The core layer 18 may be formed from nylon(e.g., nylon 12 and the like). The backing layer 20 may be formed fromnylon (e.g., nylon 6, nylon 11, nylon 12, nylon 66, nylon 612, and/orcombinations thereof). The core tube 12 may also be formed from anyother process or from any other materials known to those skilled in theart. The core tube 12 is generally impervious to fluid flow through thewall. The core tube 12 may have a first wall thickness 22 that isbetween 0.030-0.060 inches. However, it should be appreciated that anyother wall thickness may be used as known to those skilled in the art.

A first layer 24 extends about the core tube 12, as shown in FIGS. 1 and2. The first layer 24 is formed by braiding a plurality of first fibers26. More specifically, the first layer 24 may be a braided reinforcementthat is braided from between 12 and 36 bobbins. Preferably, the firstlayer 24 is braided from 24 bobbins. Each bobbin includes at least oneof the first fibers 26. The first fibers 26 have a linear density of atleast 15,400 denier and are applied at a first braid angle A1 of between52 and 56 degrees, relative to the central axis 14. Preferably, thefirst braid angle A1 of the first fibers is about 54 degrees, relativeto the central axis 14. Therefore, the first fibers 26 are braided andwound around the core tube 12. The tenacity (breaking force) of thefirst fibers 26 may be between 8 and 12 grams per denier (gpd). Thefirst fibers 26 may be formed from polyester, nylon, and the like. Thepolyester may be any type of industrial grade polyester known to thoseskilled in the art. The nylon may be nylon 66. However, other materialsknown to those skilled in the art may also be used.

A second layer 28 extends about an exterior surface 30 of the firstlayer 24 such that the second layer 28 is directly disposed on theexterior surface 30, as shown in FIGS. 1 and 2. The second layer 28 isformed by braiding a plurality of second fibers 27. More specifically,the second layer 28 may be a braided reinforcement that is braided frombetween 12 and 36 bobbins. Preferably, the second layer 28 is braidedfrom 24 bobbins. Each bobbin includes at least one of the second fibers27. The second fibers 27 may be formed from aramid fibers. Morespecifically, the aramid fibers may be para-aramid fibers (e.g., Kevlar®and the like). The second fibers 27 are at least 5,680 denier and areapplied over the first layer 24 at a second braid angle A2 of between 28and 32 degrees, relative to the central axis 14. Preferably, the secondbraid angle A2 is about 30 degrees, relative to the central axis 14.Therefore, the second fibers 27 are braided and wound directly aroundthe exterior surface 30 of the first layer 24. The tenacity of thesecond fibers 27 is at least 23 gpd with a maximum elongation at breakof 4%. Preferably, the maximum elongation at break of the second fibers27 is about 3.6%. The tensile strength of the second fibers 27 ispreferably between 500 and 555 gpd.

A sheath 32 extends about the second layer 28, as shown in FIGS. 1 and2. The sheath 32 may be formed from nylon. More specifically the nylonmay be nylon 6, nylon 11, nylon 12, nylon 66, nylon 612, and/orcombinations thereof. The sheath 32 may be extruded over the secondlayer 28. It should be appreciated that the sheath 32 may be appliedover the second layer 28 with any other method known to those skilled inthe art. The sheath 32 may have a second wall thickness 34 of between0.030 and 0.060 inches. Referring to FIG. 2, the sheath 32 defines aplurality of perforations 36 that extend through the wall. If any gas orfluid should seep between the sheath 32 and the core tube 12, theperforations 36 prevent a buildup of the gas and/or fluid which wouldtypically result in bubbling of the sheath 32. The sheath may becompounded to provide abrasion and chemical resistance to the supplyhose 10.

While the best modes for carrying out the invention have been describedin detail, those familiar with the art to which this invention relateswill recognize various alternative designs and embodiments forpracticing the invention within the scope of the appended claims.

1. A hydraulic supply hose extending along a central axis and defining a hollow interior, said supply hose comprising: a first layer including a plurality of first fibers braided about the hollow interior at a first angle, relative to the central axis; a second layer including a plurality of second fibers braided about the hollow interior at a second angle, relative to the central axis; wherein said first angle is substantially greater than said second angle.
 2. A supply hose, as set forth in claim 1, wherein said first angle is between 52 degrees and 56 degrees, relative to said central axis.
 3. A supply hose, as set forth in claim 1, wherein said second angle is between 28 degrees and 32 degrees, relative to said central axis.
 4. A supply hose, as set forth in claim 1, wherein a combination of said first layer and said second layer may support up to at least 4,000 pounds with a tensile strain up to at least 10% before failure.
 5. A supply hose, as set forth in claim 1, wherein each of said plurality of first fibers are at least 15400 denier.
 6. A supply hose, as set forth in claim 1, wherein each of said plurality of second fibers are at least 5680 denier.
 7. A supply hose, as set forth in claim 1, wherein said plurality of first fibers are formed from at least one of nylon and polyester.
 8. A supply hose, as set forth in claim 7, wherein said nylon is nylon
 66. 9. A supply hose, as set forth in claim 1, wherein said second fibers are formed from an aramid.
 10. A supply hose, as set forth in claim 9, wherein said aramid is a para-aramid.
 11. A supply hose, as set forth in claim 1, wherein said plurality of second fibers have a tenacity of about 23 grams per denier and a maximum elongation of about 4%.
 12. A supply hose comprising: a core tube extending along a central axis and defining a hollow interior; a first layer disposed about said core tube and presenting an exterior surface; wherein said first layer includes a plurality of first fibers braided about said core tube at a first angle of between approximately 52 degrees and 56 degrees, relative to said central axis; a second layer disposed directly on said exterior surface of said first layer; wherein said second layer includes a plurality of second fibers braided about said exterior surface of said first layer at a second angle of between approximately 28 degrees and 32 degrees, relative to said central axis; and a sheath disposed about said second layer.
 13. A supply hose, as set forth in claim 12, wherein a combination of said core tube, said first layer, said second layer, and said sheath are configured to support up to at least 4,000 pounds with a tensile strain up to at least 10% before failure
 14. A supply hose, as set forth in claim 12, wherein said core tube includes a core layer defining said hollow interior and a backing layer surrounding said core layer; wherein said first layer is disposed about said backing layer.
 15. A supply hose, as set forth in claim 14, wherein said core layer is formed from nylon
 11. 16. A supply hose, as set forth in claim 12, further comprising a sheath disposed about said second layer.
 17. A supply hose, as set forth in claim 12, wherein said sheath defines a plurality of perforations extending therethrough.
 18. A supply hose, as set forth in claim 12, wherein said sheath is formed from nylon selected from the group of nylon 6, nylon 11, nylon 66, and nylon
 612. 19. A method of installing a pump in a well, said method comprising: providing a supply hose defining a hollow interior configured for fluid to flow therethrough, wherein the supply hose includes a plurality of first fibers braided about the hollow interior at a first angle, relative to the central axis, and a plurality of second fibers braided about the first fibers at a second angle, relative to the central axis; attaching the supply hose to the pump such that the supply hose is in fluid communication with the pump; and lowering the pump into the well with the supply hose such that the weight of the pump is substantially supported by the supply hose.
 20. A method of installing a pump in a well, as set forth in claim 19, wherein the first fibers and the second fibers of the supply hose are configured such that the supply hose substantially supports the weight of the pump at a depth of at least 609.6 meters. 